"Mains Power Failure Voltage" in the context of a KUKA robot typically refers to an issue where the robot controller detects a problem with the incoming power supply voltage. This can be due to a drop in the voltage levels (brownout), a complete loss of power (blackout), or voltage fluctuations that fall outside the acceptable range for the robot's operation.

Common Causes:

1. Power Supply Issues:

   • A temporary loss of mains power or a significant drop in voltage can trigger this error.
   • Inadequate or unstable power supply to the controller might cause this issue, especially in environments with poor power quality.

2. Voltage Fluctuations:

   • Voltage surges or dips can occur due to various factors, including electrical storms, heavy machinery starting up, or issues with the local power grid.

3. Faulty Power Supply Unit (PSU):

   • The power supply unit within the KUKA controller might be failing or not delivering the correct voltage to the system.

4. Wiring or Connection Issues:

   • Loose or damaged wiring between the mains power source and the robot controller can cause voltage drops or intermittent connections.

5. Overloaded Circuit:

   • If the circuit supplying power to the robot is overloaded with other devices, it can cause voltage drops when those devices are operating.

6. UPS (Uninterruptible Power Supply) Issues:

   • If the robot is connected to a UPS, and the UPS is malfunctioning or has a depleted battery, it may not supply adequate power during a mains power failure.

Steps to Troubleshoot and Resolve:

1. Check Mains Power Supply:

   • Verify that the mains power supply to the robot is stable and within the required voltage range. This typically involves checking the voltage at the power source with a multimeter.
   • Ensure that the power supply meets the specifications required by the KUKA robot controller.

2. Inspect Power Supply Unit (PSU):

   • Check the PSU inside the controller for any signs of failure or malfunction, such as unusual noises, overheating, or indicator lights showing errors.
   • If possible, test the PSU or replace it with a known good unit to see if the issue resolves.

3. Examine Wiring and Connections:

   • Inspect all power-related wiring and connections from the mains power source to the robot controller.
   • Tighten any loose connections and replace any damaged cables that could be causing intermittent power loss or voltage drops.

4. Test for Voltage Fluctuations:

   • Use a voltage monitoring device to check for fluctuations in the mains power supply over time.
   • If significant voltage variations are detected, consider using a voltage stabilizer or power conditioner to protect the robot.

5. Evaluate Circuit Load:

   • Ensure that the circuit supplying power to the robot is not overloaded with other heavy electrical devices.
   • If necessary, redistribute the load across different circuits or ensure that the robot has a dedicated power supply.

6. Check and Maintain the UPS:

   • If the robot is connected to a UPS, ensure that the UPS is functioning correctly and that its battery is fully charged.
   • Replace the UPS battery if it’s old or no longer holding a charge effectively.